TRAINING MANUAL FOR SOLAR

PV LED LIGHTING SYSTEM

INSTALLATION
SOPAC Miscellaneous Report 682

For the Remote Communities of Pacific Island Countries

 For copies of this Manual contact

SOPAC Secretariat
Private Mail Bag, Suva
Fiji Islands
Ph: +679 338 1377
Fax: +679 337 0040

or visit SOPAC website

www.sopac.org

The funding for the printing of this manual has been provided by the Technical Centre for Agricultural
and Rural Cooperation (CTA) based in the Netherlands through collaboration with the Pacific Energy
and Gender Network (PEG). The views expressed herein can no way be taken to reflect the official
opinion of CTA.
Table of Contents

FOREWORD................................................................................................ 4

1.0 INTRODUCTION.................................................................................. 5

2.0 BASIC SOLAR PV LED LIGHTING SYSTEM COMPONENTS........... 6

2.1 Solar Panel………………………………………………………………................ 6
2.2 Sealed Lead Acid Battery……………………………………........……….……… 6
2.3 LED Lights……………………………………………………......………..……….. 6
2.4 Charge/Discharge Controller…………………………........…………….……….. 7

3.0 GENERAL INSTALLATION DETAILS................................................... 8

3.1 Planning the Installation…………………………………………..…......……….. 8
3.2 The Solar Panel……………………………………………................................. 9
3.3 Charge/Discharge Controller…………………………………..….......………….. 12
3.4 Battery……………………………………………………………......…..……….... 12
3.5 LED Lights………………………………………………………......……..……….. 12

4.0 SYSTEM PERFORMANCE AND MAINTENANCE.............................. 14

4.1 System Performance…………………………………......……………………..… 14
4.2 Maintenance….…………….............................................................................. 14

5.0 TROUBLESHOOTING......................................................................... 16
5.1 LED Lights Fail to Turn On…………………………………….......………..……. 16
5.2 Lights only on for a Short Time…….…............................................................ 16

6.0 SOME USEFUL TIPS……………………………….................………… 17

GLOSSARY…………………………………………...............................…..… 18

APPENDIX
A RECOMMENDED TOOLS FOR LIGHTING SYSTEM INSTALLATION….............…. 19
B CONTACT INFORMATION………………………………………….......................…… 20
NOTES………………………………………………………………………….................. 21

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 FOREWORD

The “Training Manual for Solar PV LED Lighting System Installation” has been developed as
part of the Pacific Micro Energy Services Companies (PMESCOs) Project. The project was
co-funded by REEEP (Renewable Energy and Energy Efficiency Partnership) and SOPAC
(Pacific Islands Applied Geoscience Commission) in collaboration with the Solomon Islands
Solar Entrepreneur, Willies Electrical and Solar Power (WILLIES) and the Kiribati Solar Energy
Company Ltd (KSEC).

The PMESCOs project created an enabling environment for the purchase of affordable, efficient
and reliable lighting needs for remote communities in the participating Pacific Island Countries
(Solomon Islands and Kiribati), through the establishment of a micro credit facility. The micro
credit facility has allowed rural communities to repay the cost of the solar PV LED lighting
systems over a two year period using cash or cash crops.

The use of solar PV LED lighting systems has contributed to the sustainable livelihoods of remote
communities through reducing reliance on imported kerosene for lighting and enhanced the
use of solar energy with linkages to agricultural activities.

The training manual has been adapted (with permission) from the Light Up the World Foundation
(LUTW) training and installation manual to assist solar entrepreneurs. The manual is particularly
relevant for remote and outer islands of Pacific Island Countries and designed to increase
their understanding and potential application of solar PV LED lighting systems. The manual
includes details of system components, correct installation, maintenance and troubleshooting
procedures. The manual will contribute to the promotion of solar PV LED lighting systems and
encourage the adoption and the application of solar energy for rural electrification.

4
1. INTRODUCTION
The purpose of the Solar PV LED Lighting System1 is to provide a complete, off the-grid lighting
solution for homes, community halls and medical clinics operating in very remote areas where
there is no grid connection and people rely on fossil fuel-base lighting such as kerosene
lanterns.

Kerosene lanterns and the like are inefficient, typically only offering one fourth of the lumens
of electric lights2, and are difficult to work, have been the cause of many household fires and
provide a poor level of light to work or read from. Women and youth are often required to
walk long distances to purchase kerosene required for household lights, particularly in remote
regions.

The Solar PV LED Lighting System installed in remote areas and outer islands of the Pacific
Islands must be:
• Reliable;
• Easy to install;
• Easy to maintain; and
• Low cost.

Low power consuming LED (Light Emitting Diode) lighting systems have been introduced
through the PMESCOs project to replace kerosene lanterns in remote locations and provide a
renewable, clean and reliable source of lighting. LED lights have the advantage over fluorescent
lights of being more effective and energy efficient.

Installation of the solar PV LED lighting systems require a basic set of tools as outlined in Annex
A.

The manual is divided into the following sections:

• Basic system overview and Parts List
• Solar Panel Installation
• Electrical Wiring
• System Powerup & Testing
• Maintenance & Troubleshooting

1
The system can be modified according to the energy needs of a household for lighting such as used in the
PMESCOs project, includes 12W solar panel, 12V 18Ah Lead Acid Battery, LED lights and charge controller.
2
Foster, R, et al, Sandia National Laboratories, “Light Emitting Diodes for Photovoltaic off-grid homes”, US Department
of Energy, January 2005.

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 2. BASIC SOLAR PV LED LIGHTING
SYSTEM COMPONENTS
2.1 Solar Panel

The Solar Panel is an energy transducer (a device that turns one form of energy into another)
and consists of an array of photovoltaic cells that collects the energy from the sun and turns it
into electrical energy. They are relatively expensive and complicated to make but simple to use
and have a good life if maintained properly.

Solar Panel Type: Monocrystalline Silicon

Output Power: 10W
Lifetime: 20 – 25 years

2.2 Sealed Lead Acid Battery

A Sealed Lead Acid Battery is recommended for use in a solar PV LED lighting system.
Sealed lead acid batteries are also refereed to as maintenance free batteries as they require
no maintenance. These types of batteries are suitable for remote areas where there is no
technician available to provide maintenance. The battery stores electricity produced by the
solar panel for use later, such as for lighting at night.

Battey Type: Sealed Lead-Acid Battery

Capacity: 12V, 18Ah
Weight (kg): 5.8 kg
Lifetime: 5 – 7 Years or 1000 recharging cycles.

2.3 LED Lights

The LED Lights are low powered lights and require very low amounts of power to operate.
The LED is an electronic diode similar to other semiconductor diodes which are unique and
designed to convert energy from the battery into visible light.

Model: Nemalux LED

Input Voltage: 3 – 3.5V
Power Consumption (Typical): 1.8W (at full power)

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2.4 Charge/Discharge Controller
The Charge/Discharge Controller is a device used to limit the output voltage from the solar
panel to a safe level for the battery and at the same time limit the excessive discharge of the
voltage from the battery.

The Charge/Discharge Controller prevents damage to the battery from over charging or
excessive discharge that will contribute to prolonging the life of the battery.

Model: Nemalux LUTW Charge Controller

Wiring configuration:
Solar panel: single black cable
Battery: red cable to positive (+ive) pole and black
cable to negative (-ive) pole.
LED lights: Yellow /White cable



A set of solar PV LED lighting system components
sold out through the micro credit scheme for remote
communities in Malaita Province, Solomon Islands.

Set of solar PV LED lighting systems lined up for

households, Malaita Province Solomon Islands.

7
 3. GENERAL INSTALLATION DETAILS
3.1 Planning the Installation
When planning an installation, make sure to follow these installation guidelines as well as
bearing in mind that excessive distance between the solar panel, battery and lights should be
avoided so as to reduce power losses in the wiring.
• Choose a clear obstructed area to mount the solar panel;
• Choose a safe place for the battery;
• Choose a location that will give the best lighting for the LED lights; and
• Choose an accessible place for the charge/discharge controller with built-in light
switches.

Once all components have been placed and positioned, they should be mounted and wired as
shown in Figure 1. A good time for the installation is at dawn in order to maximize the number
of daylight hours for testing and fine tuning of the system once the sun is out at mid-day.

SOLAR
PANEL

LED LED
Light Light

-
4 ive
(Black)
+ive
(Red)
4
CHARGE
white CONTROLLER white

(Includes switches
yellow Plug/ for the LED Lights-2) Plug/ yellow
Connectors Connectors

Cable 3.5 meters -

ive +ive Cable 3.5 meters
(Black) (Red)

BATTERY

Figure 1: Solar PV LED lighting system installation and wiring overview.

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3.2 The Solar Panel

3.2.1 Check the polarity of solar panel with a multimeter.

The polarity of a solar panel is the arrangement of the positive pole (+ive) and the negative pole
(-ive). It is simply a way of showing the direction of the electricity flow. The solar panel has a +ive
and -ive lead. The +ive lead should be connected to the +ive pole of the controller and the -ive
lead connected to the -ive pole of the controller.

In order to double check the polarity of the solar panel, follow the instructions below:
a. Place the solar panel outdoors with the monocrystaline side facing up in a sunlit location.
This will produce a test voltage for you to measure.
b. Set the multimeter to the DC voltage range capable of measuring up to 24VDC.
c. Connect the +ive side of the multimeter to one terminal of the solar panel and the -ive side
of the multimeter to the other side.
d. If the reading is +ive (as shown in Figure 2, Left) this is the +ive side of the solar panel.
e. If the reading is -ive (as shown in Figure 3, Right) the terminal markings are incorrect and
should be marked correctly.

Figure 2: Left-proper polarity. Figure 3: Right-reversed polarity.


 


3.2.2 Aligning and Mounting the Solar Panel

3.2.2.1 For maximum solar efficiency mount the solar panel so that:
a. the photovoltaic side of the panel is directly facing in the direction of the sun.
b. It is at least 100 mm above the roof or its mounting surface so air can move all around the
panel and keep it from getting too hot.
c. It is in a clear area away from any obstructing object that could cast a shadow on the
panel.

Any shading on the solar panel will result in a dramatic decrease in output, resulting in poor
battery charging and less lighting time.

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 3.2.2.2 To mount the solar panel follow these steps:
a. Determine if your location is in the Northern or Southern hemisphere, i.e North or South of
the equator.
b. The photovoltaic panel faces due South if it is being installed in the Northern hemisphere.
c. The photovoltaic panel faces due North if it is being installed in the Southern hemisphere.
d. The tilt angle or angle of inclination should be set to an angle equivalent to the geographic
latitude coordinate of the village.

Example: In a village at 20°N latitude, the solar panel should be installed facing due South and
inclined 20° from the horizontal. In a village at 10°S latitude, it should be installed facing due
North and inclined 10o from the horizon which is shown in Fig 4.

Sun

West

South North
Horizontal Plane Horizontal Plane
East
Southern Hemisphere Northern Hemisphere

Equator

Figure 4: Solar panel orientation on both sides of equator.

The Pacific Island Countries situated South of the equator such as Kiribati, Nauru, Tuvalu and
Solomon lies at the latitude between 0° and 10°S. Whilst Fiji, Samoa and Vanuatu lies between
latitude of 10° and 20°S. Tonga and Cook Islands lie at between 20° and 25°S. Most of the
Northern Pacific countries, RMI, FSM and Palau lie at between 0° to 20°N.

Figure 5: A solar panel on a roof in the Marshall Islands.

Photo: www.islandeco.com

10
3.2.2.3 Orienting a solar panel using shades projection method.
Any material (while preferably) could be used to
build a shades projector, shown in Figure 6, as long 

as it is solid enough to keep all its wall straight. It is
important that all angles are square (including the
base), otherwise the solar panel will not be precisely
oriented.

Place the shade projector over the solar panel as

shown in Figure 7 below; then rotate them together
and/or modify their degree of inclination until there is
no projected shade at the bottom.

These adjustments should be performed ONLY when

the sun is at its highest position also known as the
Figure 6: Shades projector.
local Solar Noon Position.

Figure 7: Solar Panel with improper orientation Figure 8: Solar panel with proper orientation.
and facing the sun directly.

Determining Local Solar Noon Position

There is a very simple way to determine the local Solar Noon by averaging times of Sunrise
and Sunset. For example if Sunrise was observed at 05:32 (5:32 AM) and Sunset was observed
at 18:48 (6:48 PM) the night before. Solar Noon can be calculated by adding the two times and
dividing the result by two as it follows:

05:32 hours + 18:48 hours = 24:20 hours

Solar Noon Position Time = 24:20 / 2 = 12:10 hours (12:10 PM)

Note: minutes must not exceed 60, if this occurs, reduce minutes by 60 and add 1 to the hours.

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 3.3 Charge/Discharge Controller
The charge/discharge controller should be connected into the system according to the
instructions which are provided by the supplier of the controller. The LUTW controller has two
LED lights outputs and individual switches for each of the lights.

The charge and discharge controller should be connected to the correct sides of the solar
panel with the +ive wire on the controller connected to the +ive side of the solar panel and the
-ive wire from the controller to the -ive side of the solar panel.
Refer to 3.2.1 for the polarity of the solar panel.

The controller should be solidly mounted in a cool place, protected from the sun and rain and
as close to the battery as practical.

3.4 Battery
The safety of the sealed lead acid battery depends on where it is placed. The following
guidelines indicate things to consider when locating the battery:
a. Primarily the battery should be located in a safe, secure and well ventilated place.
b. General points for consideration include:
• Locate the battery close to the charge controller;
• Protect the battery and terminals with a non conductive material such as wool or plastic
box; and
• Avoid damaging the battery seal as batteries contain corrosive, harmful chemicals
which can cause injury.
c. DO NOT place any metal conductor directly between the +ive and -ive battery terminals.
This can cause an electrical short circuit and the resulting large current could cause the
battery to explode and/or be irreversibly damaged which can cause fire to the home.

3.5 LED Lights

3.5.1 The LED lights should be installed where required. Details of a typical
system layout are provided in Figure 1.

A basic solar PV LED lighting system is supplied with cables but in case additional cable is
required during the installation, a similar size of wire should be used. Also seek advice from the
suppliers of the solar PV LED lighting system for additional cable.

Figure 9: A solar panel ready to be aligned and mounted correctly on the roof.

12
Figure 10: Simple reinforcing wire hanger for mounting the LED lights.

Figure 11: Additional cable can be added to the solar PV LED lighting system as
shown here. A KSEC Solar Technician measured the additional cable required.

13
 4. SYSTEM PERFORMANCE AND
MAINTENANCE

4.1 SYSTEM PERFORMANCE

The LUTW Foundation LED lights provide two levels of illumination, where the level is controlled
by a switch on the controller such as shown in Figure 12.



Figure 12: A Charge/Discharge Controller with the two switches for LED lights.

The high brightness position gives more light output but drains the battery faster than the low
brightness position.
• High brightness (100%), 75 lumens light output; and
• Low brightness (25%), 20 lumens light output.

The basic solar PV LED lighting system can provide up to 14 light hours per day for two LED
lights (i.e 7 hours per light) if the system is fully charged. A good charging day is having 4 to 6
hours of good sunlight.

Where daily sunshine hours are lower, on an overcast or cloudy day the battery may not fully
recharge. In this instance the available electricity to power the lights will be limited and therefore
the user will have to minimize the use of one of the LED lights in order to have sufficient lighting
for one full night.

Additional LED lights can be added to the system but the hours of use per light will need to
be reduced.

4.2 MAINTENANCE

4.2.1 Solar Panel

Keep the upper surface of the photovoltaic panel clean. The accumulation of dust reduces the
efficiency of the panel and the amount of power it can produce. Use only water to clean the
panel every 6 months or more frequently if very dusty. Do not use any chemicals as they can
corrode the photovoltaic cells. It is best that cleaning the module is done early in the morning
before the module; the frame and the roof (if metal) become too hot.

14
Connectors to the panel may become loose over time and therefore it is best that the wires are
regularly checked, cleaned and lightly coated with grease if it in a corrosive environment.

4.2.2 LED Lights

Keep the LED light lenses clean. The accumulation of dust and dirt reduces the effective
amount of light. The lights are only meant for indoor use. They are not waterproof and should be
mounted in a dry place. If water gets inside the LED light accidentally, switch it off immediately,
open the case and let dry thoroughly before reassembling and using.

4.2.3 Battery

Sealed lead acid batteries are preferable to use as they require less maintenance and also
there is less likelihood of accidents involving spilt battery acid.

Care should be taken to avoid any accidental short circuit of the battery terminals as this will
damage the battery.

The efficiency of sealed lead-acid batteries depends on three main factors:

• Temperature;
• State of charge; and
• Recharging cycles.

4.2.3.1 Temperature
When a battery is fully charged and there is no load it will naturally discharge a small amount of
electricity. This is called “self-discharge”. Heat (temperature) increases the rate of self-discharge
and also degrades the battery by promoting the corrosion of the +ive plate grids. The self-
discharge should therefore be kept as low as possible to minimize the number of recharging
cycles and increase battery life.

Extreme cold reduces the speed at which chemical reactions occur, thus limiting the ability of
a battery to the delivery rated capacity. Extreme cold also introduces the possibility of damage
by freezing of the electrolyte. Batteries in a discharged state are particularly susceptible to
freezing damage.

A safe temperature range to operate most batteries, as recommended by battery manufacturers

is 0° to 40°C. Avoid exposing batteries to temperatures below -15°C or above 50°C as this may
damage the battery.

4.2.3.2 State of Charge

A sealed lead acid battery will gradually fail if kept in a low state of charge due to crystal growth
of lead sulphate. The accumulation of lead-sulphate on the plates insulates that portion of
the plate requiring extra power to remove the deposits. Batteries SHOULD NOT be kept in a
discharged state as this will result in permanent loss of capacity. Due to the self-discharge
property of batteries, unused spare batteries should be charged periodically. Avoid keeping the
battery in discharged state for long periods of time.

4.2.3.3 Recharging Cycle

An 18Ah 12V sealed lead acid battery typically can last 5 to 7 years or 1000 recharging cycles,
which ever comes first. If the battery is charged or discharged excessively, the excess current
will generate waste heat and form lead-sulphate that cannot be subsequently removed by
charging.

15
 5. TROUBLESHOOTING
Troubleshooting for a solar PV LED lighting system should be carried out by a trained community
or island solar technician who can operate and use a multimeter.

5.1 LED LIGHTS FAIL TO TURN ON

It is highly improbable that both lights have failed simultaneously. It is more likely that a system
problem such as broken wire, bad connection or a battery, charge/discharge controller failure
has affected both lights.

If both lights are connected and have power applied but neither light turns on, turn the power
off by disconnecting the battery and follow the steps below to check for problems.

5.1.1 Check Solar Panel

Check that the solar panel is in good condition and that nothing is obstructing it from receiving
sun light and check all the wiring at the solar panel, the charge/discharge controller and at the
battery terminals. If all the wire installation is good and LED lights do not turn on then check
the solar panel orientation as discussed in Section 3.2. If the lights still do not turn on, then
connect the LED lights straight to the battery, if the lights go on, the solar panel is damaged or
not charging and has to be replaced.

5.1.2 Check the Battery

Check the battery voltage (using the multimeter); it should be between 12.2V and 14V. If the
battery voltage is below that range then either the solar panel is not charging the battery or the
battery needs to be replaced. A typical sealed lead acid battery should last for approximately
5 to 7 years with continuos use. On the other hand if the battery voltage falls within that range,
then check the wire installation and connections, check the switches, which often can fail.

Note: When replacing the battery, replace with the same type and size of battery as was
installed with the solar PV LED lighting system.

5.2 LIGHTS ONLY ON FOR A SHORT TIME

As discussed above, during normal conditions the solar PV LED lighting system provides at
least 7 hours of light a day for one LED light. If the number of hours are reduced dramatically
(e.g 2 hours), then either the battery or the solar panel are not working properly so check the
solar panels performance and the battery as discussed in Section 5.1.1 and 5.1.2 respectively.

16
6. SOME USEFUL TIPS
In order to allow your solar PV LED lighting system to last longer and provide the best lighting
for your family at night, keep in mind the following:
a. Do not try to disconnect and move your solar PV LED lighting system around to camping
areas or other houses.
b. Do not charge other people’s battery other than the battery provided.
c. Do not connect other appliances other than LED lights.
d. Regularly check that the solar panel is not shaded from any tree or branches.
e. Check that the wires are always in tact in particular on the solar panel and at the battery
terminals.
f. Always check for wire damages.
g. Use your solar PV LED lighting system with care.

Figure 13: Solar panels put on top of roofs should be protected from
fallen branches, leaves or coconuts.

Figure 14: Do not charge other batteries other
than the battery provided with the system.
Figure 15: Do not connect your solar PV LED
lighting system with other electrical appliances,
for example CFL shown in the diagram. CFL
consumes more power (7 W) compared to LED
lights (1.8 W).

17
 GLOSSARY

AC Alternate Current.

Ampere hours (Ah) The unit of measure used for comparing the capacity or energy
content of a battery with the same output voltage.

Capacity The electric energy content of a battery expressed in “Watt

hours”. Batteries with the same output voltage also use “Ampere
hours” for comparing capacities.

DC Volts Direct Current.

Discharge The change from chemical energy within the cell into electrical
energy to operate the external circuit, for example LED lights.

Energy Transducer A device that converts one form of energy into another.

LED Light Emitting Diode – it is a semiconductor device that emits

visible light when conducting current.

Lead-sulphate A chemical compound found on the +ive and -ive plates of a

lead battery during discharging.

Multimeter Also known as a volt/ohm meter or VOM is an electronic

measuring instrument that combines several measurement
functions in one unit. A typical multimeter may include features
such as the ability to measure voltage, current and resistance.

Photovoltaic cells Also called solar cells, cells that made up a PV panel. 30 to 36
solar cells on a panel can charge a 12V battery.

Photovoltaic (PV) panel A part of a photovoltaic system that converts the energy in light
into electrical energy. Also called a solar panel or a PV panel.

Self discharge Capacity loss during storage due to internal current leakage
between the +ive and -ive plates.

Solar irradiation Emission or transfer of energy in the form of electromagnetic

waves from the sun.

State of charge Is defined as the available or remaining capacity of a battery

expressed as a percentage of its rated capacity for example,
100% or 80%.

Short circuit A short circuit is when an electric current travel along a different
path from originally intended.

Volts Is a measure of electrical pressure which is the force that

pushes electricity through a wire.

Watt A unit of power, the rate of doing work.

Watts = Amps x Volts = One Joule per second.

WattHours or Wh A measure of the capacity of a battery. The amount of work

done in one hour.

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APPENDIX A
RECOMMENDED TOOLS FOR LIGHTING SYSTEM INSTALLATION

In this section a list of the tools necessary to perform the typical installation of the complete solid
state lighting system are presented. More tools may be needed, depending on the complexity
of the installation.

High quality wire strippers (18 AWG included)

Pliers

Crimping Tool

Multiple-tips Screwdriver (User friendly)

Low cost multimeter (consider extra batteries)

Electric Drill (rechargeable batteries, 12V car adapter)

Miscellaneous wood screws, screws and nuts might be needed to install battery boxes and
solar panels respectively. They should be purchased according to the climate and type of
household construction where the installation takes place.

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 APPENDIX B

CONTACT INFOMATION
Willies Electrical & Solar Power
P.O. Box 169, Ranadi, Honiara
Solomon Islands
Tel: (677) 30508
Fax/Tel: (677) 30477
Email: dif@solomon.com.sb

Kiribati Solar Energy Company Ltd

P.O.Box 493, Betio, Tarawa
Kiribati
Tel: (686) 26058
Email: Terubentau@gmail.com

SOPAC Secretariat
Private Mail Bag, GPO
Suva, Fiji Islands
Tel: (679) 3381377
Fax: (679) 3370040
www.sopac.org

Light Up the World Foundation

ECE, 2500 University Drive NW,
Calgary, Alberta, Canada.
T2N 1N4
info@lutw.org
www.lutw.org

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NOTES

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 NOTES

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